4. Function Description of the Machine and its Components
2
3
8
6
7
9
4
1
5
Page 7 of 41
Fig. 1
External Sketch of WD500 Welding Workstation (WD400A /WD1000E are similar with WD500)
1
.
base air inlet fence
2
.
fork lift
3
.
air inlet fence in front panel
4
.
air inlet fence
5
.
front control panel
6
.
air filter inlet fence
7
.
engine left side door
8
.
front control panel cover
9
.
lift fork on the top
10
.
engine coolant filling door
11
.
muffler exhaust pipe
12
.
muffler box air inlet fence
13
.
right side door of diesel engine
14
.
engine oil ,coolant drain port
15
.
air inlet fence
15
14
13
12
11
10
Page 8 of 41
Figure 2: back of the machine
1
.
diesel fuel outlet
2
.
engine radiator air outlet
3
.
muffler exhaust pipe
4
.
lift hook
5
.
front control panel cover
1
2
3
4
5
1
Page 9 of 41
1
2
4
5
6
3
7
Page 10 of 41
Figure 3: engine left side
1
.
diesel fuel pre-filter (water separator)
2
.
air filter
3
.
manual press fuel pump
4
.
engine speed control unit
5
.
welder A
6
.
battery
7
.
engine speed adjustment knob
8
.
engine oil filter
9
.
fuel level sensor
10
.
fuel filter
1
3
8
9
10
Page 11 of 41
Figure 4: engine right side
1.
welder B
2
main power switch
3, welder power switch
4, muffler
5, engine starter
6, oil dipstick
7, fuel gauge
8, alternator for battery charging
9, diesel fuel refilling port
1
2
3
4
5
6
7
8
9
Page 12 of 41
5. Technical Parameters
5.1
Main Technical Parameters (see Table 1-2-3)
Table 1 WD400 Main Technical Parameters
Single welder
W
e
ld
e
r
Welding mode
MMA
TIG
Cellulose
OCV(vrd off)
76V
76V
76V
OCV(vrd on)
< 18V
76V
76V
Current range
30A/21.2V-400A/36V 30A/11.2V-400A/26V
30A/21.2V-400A/36V
Rated current(A)
400
310
400
310
400
310
Rated voltage(V)
36
32.4
26
22.4
36
32.4
Duty cycle
60%
100%
60%
100%
60%
100%
V-A curve
Drop
drop
flat
Dual welder (optional )
Welding mode
MMA
TIG
Cellulose
OCV(vrd off)
76V
76V
76V
OCV(vrd on)
< 18V
76V
76V
Current range
(30A/21.2V -250A/30V)×2 (30A/11.2V -250A/20V)×2
(30A/21.2V -250A/30V)×2
Rated current(A)
250
200
250
200
250
200
Rated voltage(V)
30
28
20
18
30
28
Duty cycle
60%
100%
60%
100%
60%
100%
V-A curve
Drop
drop
drop
g
en
er
at
or
Rated power
20KW
Excitation
AVR brushless excitation
frequency
50Hz
Auxiliary
power
3 phase
Single phase
16KW/400V/28.6A
cosΦ=0.8
6.9KW /230V/1*15A + 1*15A
e
ng
in
e
type
Weichai WP2.3D25E200
fuel
diesel
power
rated 23 KW standby 25KW
Rated speed
1500r/min
Start/shut off
key ,electrical start and shut off
warning
water temperature, oil pressure ,battery charging
Fuel capacity
85L
Compl
ete
machi
ne
transport
lift hook on top and truck slip at bottom
Weight/dimensi
on
700Kg/1705×820×1050 (include front control panel)
Protection/
insulation
IP23/F
Page 13 of 41
Table 2 WD500 Main Technical Parameters
Single welder
W
e
ld
e
r
Welding mode
MMA/Cellulose
TIG
FCAW
OCV(vrd off)
76V
76V
76V
OCV(vrd on)
< 18V
76V
76V
Current range
30A/21.2V-500A/40V 30A/11.2V-500A/26V
17V/60A—39V/500A
Rated current(A)
500
400
500
400
500
400
Rated voltage(V)
40
36
30
26
39
34
Duty cycle
60%
100%
60%
100%
60%
100%
V-A curve
Droop
droop
flat
Dual welder
Welding mode
MMA
TIG
FCAW
OCV(vrd off)
76V
76V
76V
OCV(vrd on)
< 18V
76V
76V
Current range
(30A/21.2V -300A/32V)×2 (30A/11.2V--300A/22V)×2
17V/60A—29V/300A
Rated current(A)
300
250
300
250
300
250
Rated voltage(V)
32
30
22
20
29
26.5
Duty cycle
60%
100%
60%
100%
60%
60%
V-A curve
Droop
droop
flat
g
en
er
at
or
Rated power
30KW
Excitation
AVR brushless excitation
frequency
50Hz
Auxiliary
power
3 phase
Single phase
22KW/400V/39.6A
cosΦ=0.8
6.9KW /230V/1*15A + 1*15A
e
ng
in
e
type
Weichai WP2.3D33E200
fuel
diesel
power
rated 30 KW standby 33KW
Rated speed
1500r/min
Start/shut off
key ,electrical start and shut off
warning
water temperature, oil pressure ,battery charging
Fuel capacity
80L
Compl
ete
machi
ne
transport
lift hook on top and truck slip at bottom
Weight/dimensi
on
760Kg/1705×820×1050 (include front panel cover )
Protection/
insulation
IP23/F
VRD function is used for MMA, Cellulose and gouging function. The OCV of TIG and FCAW
process is controlled by torch switch ,normally ,the OCV is O v before torch switch pressed
Page 14 of 41
Table 3 : WD1000E
Main Technical Parameter
Single welder ()
W
e
ld
e
r
Welding mode
MMA
TIG
cellulose
OCV(vrd off)
76V
76V
76V
OCV(vrd on)
< 18V
76V
76V
Current range
30A/21.2V-300A/32V 30A/11.2V-300A/22V
30A/21.2V-300A/32V
Rated current(A)
300
250
300
250
300
250
Rated voltage(V)
32
30
32
30
32
30
Duty cycle
60%
100%
60%
100%
60%
100%
V-A curve
Drop
drop
Drop
Four welder (operating together)
Welding mode
MMA
TIG
cellulose
OCV(vrd off)
76V
76V
76V
OCV(vrd on)
< 18V
76V
76V
Current range
(30A/21.2V -250A/30V)×4 (30A/11.2V--250A/20V)×4
(30A/21.2V -250A/30V)×4
Rated current(A)
250
200
250
200
250
200
Rated voltage(V)
30
28
20
18
30
28
Duty cycle
60%
100%
60%
100%
60%
100%
V-A curve
Drop
drop
drop
g
en
er
at
or
Rated power
40KW
Excitation
AVR brushless excitation
frequency
50Hz
Auxiliary
power
3 phase
Single phase
36KW/400V/63A
cosΦ=0.82
9.2KW /230V/1*20A + 1*20A
e
ng
in
e
type
Weichai WP2.3D48E200
fuel
diesel
power
rated 44 KW standby 48KW
Rated speed
1500r/min
Start/shut off
key ,electrical start and shut off
warning
water temperature, oil pressure ,battery charging
Fuel capacity
110L
Compl
ete
machi
ne
transport
lift hook on top and truck slip at bottom
Weight/dimensi
on
1250Kg/2000×1000×1050
Protection/
insulation
IP23/F
VRD function is used for MMA, Cellulose and gouging function. The OCV of TIG and FCAW
process is controlled by torch switch ,normally ,the OCV is O v before torch switch pressed
Page 15 of 41
5.2 External Static Characteristics of Power Supply (see Fig. 5)
Fig. 5
External Characteristics of Power Supply
5.3Machine dimension
WD400A and WD500 outline dimension
40
400
U
2
=20+0.04I
2
0
40
U
2
(V)
30
15
45
75
60
0
I
2
(A)
30
15
45
U
2
(V)
75
60
I
2
(A)
400
U
2
=10+0.04I
2
100
0
U
2
(V)
I
2
(A)
700
U
2
=14+0.05I
2
10
20
30
40
50
60
70
(
For semi-automatic welding
)
(
For manual welding
)
(
For argon-arc welding
)
Page 16 of 41
WD1000E Outline dimension
1915
995
1100
1021
1286
6.
Operation
6.1
Check before Operation
6.1.1
Check of engine oil
1)
Check engine oil level
At side of oil sump of diesel engine (Fig. 4), an oil level check dipstick is provided and the oil level
shall be between the upper limit and the lower limit marked on dipstick when the dipstick is drawn
out for observation.
Note: Check the oil level when the machine stands on the flat ground and engine is shutdown
condition!
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